1. Disconnect the Battery:
Disconnect the battery to avoid any electrical hazards.
2. Remove the Transmission Cover:
- Drain the oil from the transmission by removing the drain plug.
- Remove the transmission cover by removing the bolts that hold it in place.
- Take out the old oil filter.
3. Remove the Cam Cover:
- Use an appropriately sized Allen wrench to remove the bolts holding the cam cover.
- Remove the cam cover and gasket and place them aside.
4. Remove the Pushrods:
- Remove the pushrods by using a pushrod removal tool.
- Keep the pushrods and lifter blocks organized, matching each pushrod to its corresponding lifter block.
5. Remove the Oil Pump:
- Remove the bolts holding the oil pump cover.
- Carefully take out the oil pump assembly.
6. Inspect and Clean the Oil Pump:
- Check the oil pump for any damages or wear. Replace any damaged components as necessary.
- Thoroughly clean all parts of the oil pump using an appropriate degreaser and compressed air.
7. Install the New Oil Pump:
- Apply a thin coat of oil to the oil pump's gasket surfaces.
- Place the new oil pump into position.
- Secure it with the bolts removed earlier.
8. Reinstall the Cam Cover:
- Place the cam cover gasket in position and reinstall the cam cover.
- Secure the cover with the bolts.
9. Reinstall the Pushrods:
- Apply a thin coat of assembly lube on the pushrods and lifter blocks.
- Reinsert the pushrods and lifter blocks into their original positions.
10. Reinstall the Transmission Cover:
- Replace the new oil filter and install it before placing the transmission cover back in place.
- Secure the transmission cover with the bolts removed earlier.
11. Refill the Transmission:
- Replace the transmission oil drain plug and fill the transmission with the recommended amount of oil.
12. Reconnect the Battery:
- Connect the battery to restore power to the motorcycle.
13. Test the Oil Pump:
- Start the motorcycle and let it run for a few minutes to ensure the oil pump is working properly and there are no leaks.
By following these steps, you can successfully replace the oil pump on your 1995 Sportster.
